Xantrex XW - Manual

v Important Safety Instructions General Precautions 1. Before installing and using the XW Automatic Generator Start, read all appropriate sections of this guide. 2. If the XW Automatic Generator Start is inoperative, see “Warranty and Product Information” on page WA–1. 3. Do not dismantle the XW Aut...

Safety vi 975-0307-01-01 7. Disable the automatic starting circuit and/or disconnect the generator from its starting battery to prevent accidental starting while performing maintenance. Explosive Gas Precautions FCC Information to the User This equipment has been tested and found to comply with the ...

975-0307-01-01 vii Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v 1 Introduction Purpose - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2 System Requirements - - - - - - - - - - - - - ...

Contents viii 975-0307-01-01 Connecting the Thermostats (optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–22Connecting an External Shutdown (optional) - - - - - - - - - - - - - - - - - - - - - - - 2–22Connecting an External Manual ON/OFF Switch (optional) - - - - - - - - - - - - - 2...

Contents 975-0307-01-01 ix Gen Run Hold Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25Crank Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–25Crank Time - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ...

Contents x 975-0307-01-01 5 Troubleshooting Faults and Warnings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2 Warning Messages - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3 Fault Messages - - - - - - - - - ...

975-0307-01-01 xi Figure 1-1 XW Automatic Generator Start Basic Function - - - - - - - - - - - - - - - - - - 1–2 Figure 1-2 XW Auto Generator Start Front Panel - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Figure 1-3 XW Auto Generator Start Bottom Panel - - - - - - - - - - - - - - - - - - - - ...

975-0307-01-01 xiii Table 1-1 Front panel features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5 Table 2-1 Circuit Limitations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5 Table 2-2 Required Wiring Size Based on Length of Cable - - - -...

1 Introduction Chapter 1, “Introduction” describes the features and functions of the XW Automatic Generator Start Module. For this Topic.... See.... “Purpose” page 1–2 “System Requirements” page 1–3 “Functions” page 1–4 “Features” page 1–5

System Requirements 975-0307-01-01 1–3 System Requirements Minimum basic system components include the following. ❐ An XW Inverter/Charger ❐ An AC Generator or DC Generator ❐ An XW System Control Panel ❐ An XW Automatic Generator Start Network Communication Protocol The XW Auto Generator Start uses ...

Introduction 1–4 975-0307-01-01 Functions Generator Starting Triggers The XW Auto Generator Start can automatically start a generator in response to: • low battery voltage • high battery drain from the AC loads • a thermostat signal • a pre-programmed exercise period at a specified time of day. Gene...

Features 975-0307-01-01 1–5 Features Indicator Lights Four lights on the front panel indicate the operating status and network status of the XW Auto Generator Start. Connectors Two network ports on the bottom panel connect the XW Auto Generator Start to the Xanbus system. A 20-contact pluggable conn...

Introduction 1–6 975-0307-01-01 Bottom Panel Network Port Each network port can accept an eight-pin RJ45 plug attached to a Category 5 (CAT 5) network cable. Depending on the installation, both ports may be required. 20-contact Connector The 20-contact connector supports a wiring harness (included) ...

2 Installation Chapter 2, “Installation” contains information and procedures to install the XW Automatic Generator Start. For this Topic.... See.... “Tools and Materials Required” page 2–2 “Choosing a Location” page 2–2 “Routing the Connections” page 2–3 “Mounting the Unit” page 2–4 “Wiring to the 2...

Installation 2–2 975-0307-01-01 Preparing an Installation Before installing the XW Auto Generator Start, consider how and where the unit will be mounted. Pre-plan the connection routes between the XW Auto Generator Start, the generator, thermostats, and the XW System Control Panel. Refer to the XW P...

Preparing an Installation 975-0307-01-01 2–3 Routing the Connections Connection Types Because the XW Auto Generator Start will be part of a Xanbus system, it is necessary to consider how to route two types of connections: • connections to the generator, thermostats, and other external devices and sw...

Installation 2–4 975-0307-01-01 Installing the XW Automatic Generator Start Installation Overview Installing the XW Auto Generator Start involves the following steps: 1. Mounting the unit. 2. Connecting the wiring harness to: • the generator (page 2–8) • thermostats (optional) (page 2–22) • external...

Installing the XW Automatic Generator Start 975-0307-01-01 2–5 Wiring to the 20-contact Connector ELV Circuits ELV (Extra-Low Voltage) circuits have an open-circuit voltage of not more than 30 V rms or 42.2 VDC or peak, and are therefore not a shock hazard. Class 2 Circuits As per the US National El...

Installation 2–6 975-0307-01-01 The wires on the wiring harness can be extended to meet installation requirements. When extending the wire harness, ensure that the extension wires are the same color as the wires on the harness. To install the XW Auto Generator Start using the wiring harness: 1. Conn...

Installation 2–8 975-0307-01-01 Connecting the Generator To connect the XW Auto Generator Start to a generator, identify the start wiring configuration of the generator to be used. Generators must be auto-start capable, and generators equipped with remote operation connections are ideal. If the gene...

Installation 2–22 975-0307-01-01 Connecting the Thermostats (optional) Wires 1, 2, 3, and 4 on the wiring harness can be connected to two thermostats. Wires 1 (yellow) and 2 (gray) are intended for thermostat 1 and wires 3 (orange) and 4 (gray) are intended for thermostat 2. These wires connect to 1...

Installing the XW Automatic Generator Start 975-0307-01-01 2–23 Connecting an External Manual ON/OFF Switch (optional) The external manual ON/OFF inputs (wires 7 and 8 on the wiring harness) are intended for wiring to one or more remote ON/OFF switches for starting and stopping the generator manuall...

Installation 2–24 975-0307-01-01 Multiple generator control panels or simple contact closures can be wired to the external manual ON/OFF inputs. The XW Auto Generator Start detects if any of the contacts close and will change its operating mode to External Manual On or External Manual Off (for more ...

Installation 2–26 975-0307-01-01 Connecting the Wiring Harness to the XW Auto Generator Start After all the external connections have been wired to the wiring harness, the connector on the wiring harness must be plugged into the 20-contact connector on the XW Auto Generator Start. To connect the wir...

Installing the XW Automatic Generator Start 975-0307-01-01 2–27 Connecting the XW Auto Generator Start to the Xanbus Network To connect the XW Auto Generator Start to the Xanbus network, plug a Category 5 network cable into one of the network ports on the bottom panel of the XW Auto Generator Start....

Installation 2–28 975-0307-01-01 Verifying Power Is Available When the XW Auto Generator Start has been installed properly, the Power and Network indicator lights illuminate. If one or both lights are out, check the network connections. Check the XW Inverter/Charger to ensure it has battery power. C...

Configuration 3–2 975-0307-01-01 Overview The XW Auto Generator Start has a number of settings that must be configured to ensure that the generator starts and stops under the appropriate conditions and at the appropriate time. The XW Auto Generator Start is configured using the XW System Control Pan...

Accessing the XW Auto Generator Start Menu 975-0307-01-01 3–3 Accessing the XW Auto Generator Start Menu Figure 3-2 Accessing the XW Automatic Generator Start Menu To access the XW Auto Gen Start Menu, start from the XW System Home Screen.... Enter To view the Select Device Menu, press the Enter But...

Configuration 3–4 975-0307-01-01 The XW Auto Gen Start Menu The XW Auto Gen Start menu provides the ability to configure the changeable parameters, select the generator’s operating mode, clear fault warnings and view device information. The XW Auto Gen Start Menu Home Screen is divided into five sec...

The XW Auto Gen Start Menu 975-0307-01-01 3–7 The Configuration Menu The Configuration Menu is where specific start-stop parameters are set. This menu contains the following settings: • QT EN • QT Begin • QT END • Gen Type • Cfg Trigger • Cfg Gen • Multi-unit Config • Restore Defaults QT En Full nam...

Configuration 3–8 975-0307-01-01 Sometimes automatic start or automatic stop triggers may overlap with the beginning and end of quiet time. Three different quiet time scenarios affect when the generator stops and starts. 1. If quiet time begins after the XW Auto Generator Start has started the gener...

The XW Auto Gen Start Menu 975-0307-01-01 3–9 QT End Full name Quiet Time End Purpose “QT End” is a changeable setting that defines the end of quiet time. This setting also requires a setting for “QT Begin”. Dependencies “QT End” functions only if the XW Auto Generator Start is in Automatic mode. Th...

The XW Auto Gen Start Menu 975-0307-01-01 3–11 Cfg Trigger Menu The Cfg Trigger menu contains the settings for automatically starting and stopping the generator. This menu allows the adjustment of the default settings for battery voltage, thermostat ON/OFF signals, inverter load, and battery chargin...

Configuration 3–12 975-0307-01-01 Start DCV 30 sec Full Name Starting Battery Voltage—30 seconds Purpose The “Start DCV 30 sec” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 30 seconds. The XW ...

The XW Auto Gen Start Menu 975-0307-01-01 3–13 Start DCV 15 min Full Name Starting Battery Voltage—15 minutes Purpose The “Start DCV 15 min” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 15 min...

Configuration 3–14 975-0307-01-01 Start DCV 2 hr Full name Starting Battery Voltage—2 hours Purpose The “Start DCV 2 hr” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 2 hours. Dependencies The ...

The XW Auto Gen Start Menu 975-0307-01-01 3–15 Start DCV 24 hr Full name Starting Battery Voltage—24 hours Purpose The “Start DCV 24 hr” trigger enables the XW Auto Generator Start to start the generator whenever the battery voltage reaches or drops below a pre-set voltage for longer than 24 hours. ...

Configuration 3–16 975-0307-01-01 Stop Float Full name Stop at Float Charge Stage Purpose The “Stop Float” trigger allows the XW Auto Generator Start to stop the generator when the inverter/charger has recharged the batteries to the Float stage. Considerations “Stop Float” or “Stop Absorb” would typ...

The XW Auto Gen Start Menu 975-0307-01-01 3–17 charge. If the generator is the only charging source, Stop Absorption will leave the batteries consistently undercharged and may shorten the battery life. Alternately, Stop Absorption can be useful during utility outages, when it is desired to keep the ...

Configuration 3–18 975-0307-01-01 Temp1 Full name Thermostat 1 Purpose The “Temp1” trigger enables the generator to start in response to a signal from a thermostat. With “Temp1” set to [Enabled], the XW Auto Generator Start will start the generator to help power the item controlled by that thermosta...

The XW Auto Gen Start Menu 975-0307-01-01 3–19 Dependencies The “Load” trigger requires the XW Auto Generator Start to be in Automatic mode and needs parameters to be set for both the “Start Load” and “Stop Load” triggers. Start Load Full name Start on Inverter Load Current Purpose The “Start Load” ...

Configuration 3–20 975-0307-01-01 Stop Load Full name Stop on Inverter Load Current Purpose The “Stop Load” trigger enables the XW Auto Generator Start to stop the generator when the AC load falls below a specific level for 1 minute. The “Stop Load” setting applies to situations when the XW Auto Gen...

The XW Auto Gen Start Menu 975-0307-01-01 3–21 Starter Cool Down Purpose The Starter Cool Down setting allows an interval to be set between start attempts if the generator fails to start on the first attempt. This time period allows the start motor to cool sufficiently before the XW Auto Generator S...

Configuration 3–22 975-0307-01-01 Max Run Time Full name Maximum Generator Run Time Purpose “Max Run Time” allows a limit to be set on how long the generator will run. This setting overrides any automatic start triggers. For example, if the generator starts in response to low battery voltage, and th...

The XW Auto Gen Start Menu 975-0307-01-01 3–23 Dependencies The “Exercise Per” trigger requires parameters to be set in the “Exercise Dur” and “Exercise Time” menu items. Considerations Generators need to run regularly in order to maintain mechanical health and performance. If the generator isn’t ne...

Configuration 3–24 975-0307-01-01 Exercise Time Purpose “Exercise Time” sets the time of day that the XW Auto Generator Start exercises the generator. The “Exercise Time” trigger requires that any parameter other than “0” be set in “Exercise Per” and a value be set in the “Exercise Dur” trigger. Con...

The XW Auto Gen Start Menu 975-0307-01-01 3–25 Gen Run Hold Time Full name Generator Run Signal Hold Time Purpose “Gen Run Hold Time” specifies the length of time the generator run signal (or B+ or hour meter signal) must be active before the XW Auto Generator Start considers the generator to be run...

Configuration 3–26 975-0307-01-01 Crank Retry Time Purpose “Crank Retry Time” specifies the length of time the Start relay is engaged (and cranking the starter motor) for the second and subsequent attempts to start the generator, in cases when the generator fails to start on the first attempt. Consi...

The XW Auto Gen Start Menu 975-0307-01-01 3–27 Multi-unit Config “Multi-unit Config” provides the means to identify multiple units within the same configuration. Dev Name The “Dev Name”, or Device Name, menu item gives each Xanbus-enabled device a unique identifiable name. This makes each device eas...

Configuration 3–28 975-0307-01-01 Generator This generator name is used by the XW inverter/charger to identify which generator is connected to the AC2 input. It is only necessary to change this setting in installations with more than one XW Auto Generator Start in a system. In this case, the “genera...

The XW Auto Gen Start Menu 975-0307-01-01 3–29 Time feature, which prevents the generator from starting during evening hours or other inconvenient times (see “QT Begin” on page 3–8, “QT End” on page 3–9, and “Using Quiet Time” on page 4–4). Automatic Mode Overrides When the XW Auto Generator Start i...

Configuration 3–30 975-0307-01-01 Manual Off Mode Selecting Manual Off Mode overrides the automatic stop settings and manually stops the generator. Manual Off must be selected to stop the generator when the generator has been started manually. The XW Auto Generator Start will not automatically start...

The XW Auto Gen Start Menu 975-0307-01-01 3–31 View Event Log Purpose The Event Log displays the last 20 XW Auto Generator Start events for reference. Events can include: • Starting and stopping the generator. • Trigger events. See Table 3-2 for a detailed list of trigger events. • Changing the syst...

Configuration 3–32 975-0307-01-01 User Settings Use this table to record any customized XW Auto Generator Start settings for future reference. Table 3-3 Generator Configuration Settings, Values, Defaults, and User Settings Setting Values Default User Setting Main Menu Items: GenMode ManualOn, Manual...

Operation 4–2 975-0307-01-01 Accessing the XW Auto Generator Start Home Screen Use the XW Auto Generator Start Home Screen to view basic operational status information for the generator. The XW Auto Generator Start Home Screen displays the generator start settings (i.e., ManualOff), the generator st...

Starting and Stopping the Generator 975-0307-01-01 4–3 Starting and Stopping the Generator Use the XW Auto Generator Start to start or stop the generator manually using the XW System Control Panel or automatically in response to an electrical system condition. To set the XW Auto Generator Start to s...

Operation 4–4 975-0307-01-01 Using Quiet Time Use the Quiet Time feature to ensure that the XW Auto Generator Start will not start the generator during the night or during times that conflict with local noise restrictions. Using Quiet Time involves three steps. 1. “QT En” must be set to [Enabled]. T...

Modes of Operation 975-0307-01-01 4–5 3. Use the navigation buttons to select the minutes, then press Enter. If the 24-hour clock is being used, go to step 5. 4. Use the navigation buttons to select AM or PM, then press Enter. 5. Press Exit twice to return to the System Home screen. To set the end o...

Operation 4–6 975-0307-01-01 Putting the XW Auto Generator Start in Standby Mode Use the XW System Control Panel to put the XW Auto Generator Start into Standby mode. Figure 4-4 Changing the Mode to Standby XW System Home Screen Select Device Menu XW Auto Generator Start Settings Menus Press the Ent...

Modes of Operation 975-0307-01-01 4–7 Returning the XW Auto Generator Start to Operating Mode Use the XW System Control Panel to return the XW Auto Generator Start to Operating mode. Figure 4-5 Returning the Mode to Operating XW System Home Screen XW Auto Generator Start Settings Menu Press the Ente...

Troubleshooting 5–2 975-0307-01-01 Faults and Warnings Under certain conditions, the XW Auto Generator Start generates a fault or warning message. These messages appear on the XW System Control Panel. Acknowledging messages When a fault or warning message appears, it will remain on the screen until ...

Warning Messages 975-0307-01-01 5–3 To view a fault list or warning list: 1. On the Select Device menu, highlight System and press Enter. 2. On the System Settings menu, highlight View Fault List or View Warning List. 3. Press Enter. Warning Messages Table 5-1 provides details and suggests action fo...

Troubleshooting 5–6 975-0307-01-01 Fault Messages When the XW Auto Generator Start detects a fault condition, it stops the generator. The red Fault light also comes on, and the XW System Control Panel displays a fault message. The XW Auto Generator Start remembers the GenMode that it was in at the t...

A Specifications Appendix A contains the electrical, mechanical, and environmental specifications for the XW Auto Generator Start . All specifications are subject to change without notice. For this Topic.... See.... “Electrical Specifications” page A–2 “Mechanical Specifications” page A–3 “Environme...

Specifications A–2 975-0307-01-01 Electrical Specifications *Limited to Class 2 levels (100 VA) as in Chapter 2, page 2–5. Nominal input network voltage 15 Vdc Maximum operating current 200 mA @ nominal input network voltage Relay contact voltage rating 12 Vdc, 30 Vdc max.* Maximum relay contact cur...

Mechanical Specifications 975-0307-01-01 A–3 Mechanical Specifications Dimensions 3 ¾ × 5 ¾ x 1 ½(95.5 × 146 × 37 mm) Weight 0.5 lb. (225 g) Mounting 4x #6 screws Connectors 2x Xanbus: RJ45—8 pins1x 20-contact pluggable connector (Tyco Mate’n’ Lok 2 connector) Figure A-1 XW Auto Generator Start Dime...

Specifications A–4 975-0307-01-01 Environmental Specifications Regulatory Compliance Operating temperature -4 to 122 °F (-20 to 50 °C) Storage temperature -40 to 185 °F (-40 to 85 °C) Maximum case temperature 140 °F (60 °C) Operating humidity 5 to 95% Storage humidity 5 to 95% Ignition protection No...

Generator Auto Start Requirements and Types B–2 975-0307-01-01 Recommended Features In order for the generator to be automatically started by the XW Auto Generator Start, it must include electric start and an automatic choke. An automatic primer system may also be required on natural gas and propane...

Generator Starting Types 975-0307-01-01 B–3 Two Wire The two-wire type is suitable for generators that are fully automatic. This merely requires two wires to be connected together for the generator to start and run. Separating the wires stops the generator. Some generators use a momentary two-wire c...

Generator Auto Start Requirements and Types B–4 975-0307-01-01 Connection The common wire from the generator should connect to the common connections of both Relay 1 and Relay 2 (wires 16 and 18 respectively). The start wire from the generator connects to the normally open contact of Relay 2 and the...

C Relay Timing Appendix C contains information about relay configuration and timing for each major type of XW Auto Generator Start starting mode. This information applies to each of the generator types described from page 2–9 to page 2–21. For this Topic.... See.... “RunMode” page C–2 “MomentaryRun ...

Relay Timing C–2 975-0307-01-01 RunMode For generators with RunMode starting types (Types 7 and 8): • Relay 1 (RunStop relay) can be used for two-wire configured generators. • Relay 1 (RunStop) and Relay 2 (Start) can be used with a common ground for three-wire configured generators. • The Preheat w...

MomentaryRun Mode 975-0307-01-01 C–3 MomentaryRun Mode For generators with MomentaryRun mode starting types (Type 11): • Relay 1 (Run/Stop relay) can be used for two-wire configured generators. • Relay 2 has no unique function in this configuration, but it is easiest to leave it doing the cranking s...

Relay Timing C–4 975-0307-01-01 GlowStop Mode For generators with GlowStop mode starting types (Types 1, 2, 3, 6, 12): • Relay 1 (Stop) and Relay 2 (Start) can be used with a common ground for three-wire configured generators. • The Preheat signal shows up on Relay 1 and also Relay 3 (if enabled) so...

PulseStop Mode 975-0307-01-01 C–5 • The “Delay” refers to the “Preheat to Crank Delay” and may be zero. • Cranking will cease when the generator run signal goes high for the specified hold time or when the crank time has elapsed. • To get the ShutDown Bypass on Relay 3 with no preheat, Relay 3 must ...

975-0307-01-01 WA–1 Warranty and Return Information Warranty What does this warranty cover? This Limited Warranty is provided by Xantrex Technology, Inc. ("Xantrex") and covers defects in workmanship and materials in your XW Automatic Generator Start. This warranty period lasts for 5 years f...

Warranty and Return WA–2 975-0307-01-01 What proof of purchase is required? In any warranty claim, dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex. Proof of purchase may be in any one of the...

Warranty and Return 975-0307-01-01 WA–3 Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS, OBLIGATIONS AND LI...

Warranty and Return WA–4 975-0307-01-01 When you contact Xantrex to obtain service, please have your instruction manual ready for reference and be prepared to supply:• The serial number of your product • Information about the installation and use of the unit • Information about the failure and/or re...

Warranty and Return 975-0307-01-01 WA–5 Information About Your System As soon as you open your XW Automatic Generator Start package, record the following information and be sure to keep your proof of purchase. If you need to contact Customer Service, please record the following details before callin...

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